Methods and apparatus for forming a composite component

Abstract

A mould for a composite component having a fillet joint, the mould including a mould body having a cavity within which the component is formed, and an insert mating with the mould body and including a forming surface against which, in use, the fillet of the component fillet joint is formed. The insert may be thermally insulating and highly rigid. A method of forming a composite component having a fillet joint using a mould, the method including forcing a surface of the fillet region of the component to adopt a non constant radius of curvature while the component is inside the mould during the cure process is also provided. Additionally, a method of forming a composite component having a fillet joint that is defined between first and second legs the method including placing the legs of the component in bending during cure of the component is described.

Description

[0001]The present invention relates to methods for forming a composite component having a fillet joint, including for example composite components having “T” or “L” joints. The present invention also relates to apparatus in the form of moulds for forming such components.[0002]Organic matrix composite materials can offer significant advantages over metallic alternatives for component parts of a gas turbine engine, principally in reducing the overall weight of the engine. Many such components include joint regions in the form of a “T” or “L” having a fillet. An exemplary process for forming such components is described below, with reference to FIGS. 1 to 5.[0003]FIG. 1 illustrates one half of a lightweight mould tooling 2 for a composite “T” joint. The second half of the mould tooling 2 is a mirror image along the axis 3. The tooling 2 defines first and second legs 4, 6, of the composite “T” joint component 8 as well as a fillet region 10 between the first and second legs 4, 6. The fi...

AI Technical Summary

Benefits of technology

[0002]Organic matrix composite materials can offer significant advantages over metallic alternatives for component parts of a gas turbine engine, principally in reducing the overall weight of the engine. Many such components include joint regions in the form of a “T” or “L” having a fillet. An exemplary process for forming such components is described below, with reference to FIGS. 1 to 5.

[0029]There may also be provided a method of forming a composite component having a fillet joint that is defined between first and second legs, the method comprising reducing the thickness of the component at the fillet region, such that the cross section of the component is substantially uniform across the first and second legs and the fillet region of the component. A more uniform cross section may achieve reduced component shrinkage and more even resin flow during resin impregnation.

Problems solved by technology

The insert may thus provide rigidity to the mould at the fillet region, where deformation of the mould is most damaging to the eventual properties of the component to be formed.

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